Note: Descriptions are shown in the official language in which they were submitted.
,_ ~' ~ ~' ~ ~ ~ ~ 920.00430
Case 186
-1-
WINDOW OPERATOR
I~KGROUND OF THE INVENTION
Technical Field
The present invention is directed toward window operators, and
more particularly toward window operators wherein the operating
mechanism is supported directly by the cover and the base. The present
invention is also directed toward window operators having reduced air/water
infiltration.
Windows are commonly constructed having a frame and a sash.
The sash is pivotally secured to the frame for motion between a closed
position, wherein the sash fits substantially within the frame, and an open
position, wherein the sash is rotated relative to the frame so that the sash
is not substantially within the frame.
Window operators used to control the movement of the sash
between the open and closed positions are well known in the art. A window
operator typically has a mounting base with a flat planar bottom secured to
a corresponding flat planar surface on a sill of the frame. The mounting base
rotatably mounts a gear or gear train and an arm. The gear or gear train
meshes with a worm on a worm shaft having either a manually operated
handle or motorized controller attached thereto. The arm is operatively
connected to the sash of the window whereby rotation of the worm shaft
results in rotation of the gear or gear train and the arm for movement of the
window between the open and closed positions. Examples of typical
manually operated window operators can be found in U.S. Patent Nos.
4,253,276, 4,266,371, 4,445,794 and 4,845,830.
. 2177895
i
_2_
As illustrated in greater detail in U.S. Patent Nos. 4,445,794
and 4,845,830, window operators are typically manufactured with the worm
mounted in an upwardly angled generally tubular housing integrally formed
in the base. Through an aperture in the housing, the worm meshes with the
gear or, alternatively, the gear train. The gear is operably associated with
the arm such that rotation of the worm results in rotation of the gear and
associated arm about a fixed pivot pin.
To secure the worm in place in the tubular housing, a retainer
bearing is threaded into position at an open end of the housing. The
threaded retainer bearing, as shown in U.S. Patent No. 4,253,276, may be
held in place by use of an additional structural element, such as a locking
pin, wedged between the threads of the bearing and the housing. Use of
the locking pin may be avoided through the use of a specially shaped
retainer bearing and limited deformation of the housing, such as shown in
U.S. Patent No. 4,505,601. Yet another alternative locking arrangement is
shown in U.S. Patent No. 4,445,794, wherein the retainer bearing locks the
worm in place by stripping the threads at the open end of the housing as the
retainer bearing is advanced into the housing
To install the assembled operator to the window, the flat planar
bottom surface of the operator is placed against the flat planar bottom
surface of a window fame sill. A gasket may be placed around the rear of
the operator and between the operator and the sill. The base is then
secured against the sill through the use of fasteners, such as screws,
disposed through apertures in the base.
The above window operators are hard to make, and are
consequently expensive to make. Cores or paddles must be used to shape
the tubular housing.
Moreover, additional manufacturing steps must be performed
and additional costs must be incurred because a separate, threaded retainer
~. 217 7 8 9 5 920.00430
Case 186
-3-
bearing is required to hold the worm in the tubular housing. Use of a
separate retainer bearing increases the part count and the complexity of the
assembly process. Furthermore, because a threaded retainer bearing is
commonly used, additional preparatory machining steps must be performed
on the tubular housing prior to assembly. Costs may be increased even
further if an advanced locking mechanism, such as that shown in U.S.
Patent No. 4,505,601, is used because of the sophistication of the retainer
bearing used and the assembly steps required.
Additionally, by securing the arm to the base using a simple pin,
the operator is sensitive to variations in the tolerance of the constituent
pieces and in the manufacturing processes. Therefore, in order to control
the sensitivity of the device, as expressed in the gear arm backlash,
tolerances and processes must be kept within narrowly defined limits. By
restricting the range of allowable tolerances and processes, however, the
cost per operator is necessarily increased.
Furthermore, the design of the above operators allows for air
and water to infiltrate through the operator. Use of a retainer bearing
normally prevents the operator from being assembled with a seal which acts
to prevent substantial air flow through the worm housing opening.
Additionally, air and/or water may infiltrate around the rear of the operator
and between the bottom of the base and the flat planar surface of the
window frame sill.
Attempts have been made in the industry to address some of
these problems. For example, an operator has been designed which uses a
conventional tubular worm housing, similar to that shown in U.S. Patent No.
4,266,371, but in combination with an arm which is secured between
mating interior surfaces of the cover and the base. In particular, a central
post depends from an interior surface of the cover through an aperture in the
base. The arm having a gear and a bearing associated therewith is pivotally
21 7 7 8 9 5 s2o.oo4so
Case 186
mounted on the central post. The arm is secured in place by passing the
central post through the aperture, and then riveting the post in place.
Additionally, this operator has a rearwardly protruding edge
integral with the base disposed around the rearwardly facing surface of the
base. A gasket may be placed around the rearwardly protruding edge to
limit the infiltration of water and air around the operator.
However, this operator still presents all of the problems outlined
above when a conventional worm housing integral with the base is used.
Additionally, this operator fails to address the problem of infiltration of
air
and/or water at the base/sill interface.
The present invention is directed toward overcoming one or
more of the problems discussed above.
SUMMARY OF THE INVENTION
In one aspect of the invention, an operator for controlling the
movement of a window sash relative to a frame between open and closed
positions includes a base attachable to the frame and having a first support
surface, and a cover secured to the base and having a second support
surface with a hole therethrough defining an internal shoulder, the second
support surface mating with the first support surface. An arm is pivotally
secured to the base anti attachable to the sash to control the movement of
the sash between open and closed positions. A worm driveably engages the
arm. The worm has a worm shaft-and a worm shoulder disposed on the
worm shaft. The worm is directly supported by the first and second
surfaces at one end and the worm shoulder engages the internal shoulder as
the worm shaft protruding from the hole.
In another aspect of the invention, an operator for controlling
the movement of a window sash relative to a frame between open and
closed positions comprises a base attachable to the frame and having a first
2177895
-5-
support surface and an aperture, and a cover secured to the base and having
a second support surface with a hole therethrough defining an internal
shoulder, the second support surface mating with the first support surface.
A post extends from the cover and through the aperture. An arm is pivotally
secured to the post and attachable to the sash to control the movement of
the sash between open and closed positions. A worm driveably engages the
arm and includes a worm shaft and a worm shoulder disposed on the worm
shaft. The worm is directly supported by the first and second surfaces at
one end and the worm shoulder engages the internal shoulder with the worm
shaft protruding from the hole.
In an additional aspect of the invention, a method of
manufacturing a window operator is provided wherein the operator includes
a base attachable to a frame and having a first support surface and a
plurality of apertures, a cover secured to the base and having a second
support surface with a hole therethrough defining an internal shoulder, the
second support surface mating with the first support surface, a central post
and a plurality of fastener posts extending from the cover and through the
plurality of apertures, an arm pivotally secured to the central post and
attachable to a sash to control the movement of a sash between open and
closed positions, and a worm driveably engaging said arm and having a
worm shaft and a worm shoulder disposed on the worm shaft, said worm
directly supported by the first and second surfaces at one end and the worm
shoulder engaging the internal shoulder with the worm shaft protruding from
the hole. The method includes the steps of passing the worm shaft through
the hole with the worm shoulder engaging the internal shoulder and the
worm disposed against the first support surface, fitting the arm to the
central post, the arm in driveable engagement with the worm, placing the
base and the cover together with the worm disposed between the first and
second support surfaces and the central post and plurality of fastener posts
2977$95 9Case0186
-6-
protruding through the plurality of apertures, forming the central post,
controlling the time and force applied in said central post forming step to
eliminate the axial play along the central post, and securing said plurality
of
fastener posts.
In a further aspect of the invention, an operator for use with a
window having a frame with a raised surface protruding from a frame sill and
a sash moveable relative to the frame between open and closed positions
includes a base having an interior support surface and a bottom exterior
surface with a slot therein, the base attached to the frame with the raised
surface fitting substantially within the slot. An arm is pivotally secured to
the base and attachable to the sash to control the movement of the sash
between open and closed positions. A worm is disposed within the interior
support surface and driveably engages the arm.
In another aspect of the invention, an operator for use with a
window having a frame with a raised surface protruding from a frame sill and
a sash moveable relative to the frame between open and closed positions
includes a base having a first support surtace and a bottom exterior surface
with a slot therein, the base attached to the frame with the raised surface
fitting substantially within the slot, and a cover secured to the base and
having a second support surface with a hole therethrough defining an
internal shoulder, the second support surface mating with the first support
surface. An arm is pivotally secured to the base and attachable to the sash
to control the movement of the sash between opera and closed positions.
A worm driveably engages the arm and has a worm shaft and a worm
shoulder disposed on the worm shaft. The worm is directly supported by
the first and second surfaces at one end and the worm shoulder engages the
internal shoulder with the worm shaft protruding from the hole.
CA 02177895 2002-02-06
-6A-
In another broad aspect of the invention, an operator for
controlling the movement of a window sash relative to a frame between
open and closed positions includes a base attachable to a frame with a slot
therein. The slot is formed within the base continuously from a first edge
of the base to a second edge of the base so as to be capable of engaging
a raised portion of a window to provide a means for allowing attachment of
the operator to a window and to prevent substantial infiltration of air and
water through the operator when the base is attached to a window. The
base has a first support surface and a cover is secured to the base. An arm
is pivotally secured to the base and attachable to a sash to control the
movement of a sash between open and closed positions, and a worm
drivably engages the arm.
The invention further provides an operator for controlling the
movement of a window sash relative to a frame between open and closed
positions, which comprises a base attachable to a frame with a slot therein,
wherein the slot is formed within the base continuously from a first edge of
the base to a second edge of the base so as to be capable of engaging a
raised portion of a window to provide a means for allowing attachment of
the operator to a window and to prevent substantial infiltration of air and
water through the operator when the base is attached to a window. The
base has a first support surface and an aperture. A cover is secured to the
base and has a second support surface with a hole therethrough defining an
internal shoulder, the second support surface mating with the first support
surface. A post extends from the cover and through the aperture, and an
arm is pivotally secured to the post and attachable to a sash to control the
movement of a sash between open and closed positions. A worm drivably
engages the arm and has a worm shaft and a worm shoulder disposed on
the worm shaft, with the worm directly supported by the first and second
surfaces at one end and the worm shoulder engaging the internal shoulder
with the worm shaft protruding from the hole.
CA 02177895 2002-02-06
-6B-
In another aspect of the invention, an operator and window
frame for a window is disclosed having a sash moveable relative to the
frame between open and closed positions. The combination comprises a
window frame with a raised surface protruding therefrom, and a base having
an interior support surface and a bottom exterior support surface with a slot
therein. The base is attached to the frame with the raised surface fitting
substantially within the slot wherein the slot is formed within the base
continuously from a first edge of the base to a second edge of the base so
as to be capable of engaging a raised portion of a window to prevent
substantial infiltration of air and water through the operator when the base
is attached to a window. The combination further comprises an arm
pivotally secured to the base and attachable to a sash to control the
movement of a sash between open and closed positions, and a worm
disposed within the interior support surface and drivably engaging the arm.
The invention further provides an operator for controlling the
movement of a window sash relative to a window frame between open and
closed positions. The operator comprises a base having a bottom surface
capable of being supported by and attached to a window frame and having
an upper surface with at least one depressed section. A cover is provided
wherein front and side portions of the cover contact a portion of the
periphery of the base along a base mating shoulder which is formed in the
cover and mates with the upper surface of the base to support the cover on
the base and define an inner cavity between the cover and the base for
housing a worm and a worm engaging arm. The cover has an angled tubular
member mated with the depressed section of the base to form a worm
enclosure with the depressed section of the base, and the cover has a
protruding stop at the baclk end of the worm enclosure and a wall defining
a wall aperture, which wall aperture is completely within the cover at the
front end of the worm enclosure. A worm engaging arm is pivotally secured
between the base and the cover and is capable of being attached to a sash
CA 02177895 2002-02-06
-6C-
to control the movement of a sash between open and closed positions. A
separate bushing defines a bushing aperture for a worm shaft, the bushing
being larger than the wall aperture and adjacent the wall and within the inner
cavity so that the wall retains the bushing. A worm drivably engages the
arm and has a worm shaft and a worm shoulder disposed on the worm
shaft, the worm being positioned in the worm enclosure with one end being
retained by the stop and the other end being retained by the bushing, with
the worm shaft protruding through the bushing aperture and the wall
aperture. The worm enclosure, stop and bushing maintain axial and
transverse positioning of the worm, and the back end of the cover is spaced
apart from the base by the protruding stop being in contact with the upper
surface.
There is further disclosed a window operator for attachment to a
window having a raised portion. The operator comprises a base which is
defined as a single piece having an interior support surface, a plurality of
fastener post apertures and a bottom exterior surface with a slot therein,
and wherein the slot is formed within the bottom exterior surface of the
base continuously from a first edge of the base to a second edge of the base
so as to be capable of engaging a raised portion of a window to provide a
means for allowing attachment of the operator to a window and to prevent
substantial infiltration of air and water through the operator when the base
is attached to a window. A depressed stop support surface is defined
within the base. A cover having a plurality of fastener posts is provided,
and an interlocking lip for receiving the base. An arm is pivotally secured to
the base, and a worm disposed within the interior support surface and
drivably engaging the arm wherein the arm is capable of being adapted to
a sash for movement between open and closed positions, such that the
depressed stop support surface prevents axial and transverse motion of the
worm.
.?.177895 9Case0186
_7_
It is an object of the invention to provide a window operator
using parts which are easier and less expensive to manufacture and
assemble.
It is a further object of the invention to provide a window
operator which is less sensitive to tolerance or assembly process variations.
It is also an object of the invention to provide a window
operator which prevents substantial air and water infiltration therethrough.
It is additionally an object of the invention to provide a window
operator system with a complete sealing surface at the system/window
interface which prevents substantial air and water infiltration therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is an exploded perspective view of an exemplary
embodiment of the present invention;
Fig. 2 is a bottom plan view of a cover according to an
exemplary embodiment of the present invention with a worm disposed in a
support surface;
Fig. 3 is a plan view of a base of the present invention;
Fig. 4 is a bottom plan view of an assembled operator according
to the present invention with the arm partially shown;
Fig. 5 is ~ cross-sectional view taken along line 5-5 in Fig. 4;
Fig. 6 is a perspective view of an exemplary embodiment of the
present invention installed to a window having a frame and a sash;
Fig. 7 is cross-sectional view of a window showing an
exemplary embodiment of the present invention installed therein with the
arm and part of the handle removed;
Fig. 8 is a plan view of an exemplary embodiment of a window
operator gasket fitting tool for use with an exemplary embodiment of the
present invention;
21 l l 8 9 5 920.00430
Case 186
_g_
Fig. 9 is a side view of the window operator gasket fitting tool;
Fig. 10 is a cross-sectional view of the window operator gasket
fitting tool taken along line 10-10 in Fig. 9;
Fig. 11 is cross-sectional view of a window and a window
operator gasket fitting tool showing the window operator gasket fitting tool
in an intermediate position relative to an opening in a sill of the window;
and
Fig. 12. is a partial elevation view showing a gasket fitted
around an opening in a window sill.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of the present invention is shown
generally at 10 in Fig. 1. A cover 12 is attached to a base 14. Disposed
between mating surfaces of the cover 12 and the base 14 is a worm 16
having a worm shaft 18 extending through an aperture 20 in the cover 12.
An arm 22 is also pivotally secured between the cover 12 and the base 14.
The arm 22 is driveably engaged by the worm 16 at one end and is capable
of being secured to a rail 24 of a sash 26 at the other (see Fig. 6).
More specifically, referring to Figs. 1, 2 and 5, the cover 12,
preferably of a zinc die cast manufacture, has a central tapered cylindrical
post 28 and four tapered cylindrical fastener posts 30 protruding outwardly
from an interior side of,the cover 12. The fastener posts 30 are spaced to
roughly coincide with the four corners of the cover 12.
The cover 12 also has an angled tubular surface 32. At one
end of the tubular surface 32 is the aperture 20. The aperture 20 is formed
as the intersection of a circular cylinder and an elliptical cylinder. A wall
transverse to the axis of the tubular surface 32 surrounds the aperture 20
and defines an internal shoulder 34 (see Fig. 5). At the second end of the
tubular surface 32 is an outwardly protruding stop 36. The stop 36 has a
partially cylindrical surface 38 preferably co-axial with the axis of tubular
217 7 8 9 5 g Case0~86
_g_
surface 32 and capable of contacting a first end of the worm 16 (See Fig.
5).
The worm 16 is disposed within the tubular surface 32 such
that the worm shaft 18 protrudes from the aperture 20. A frustoconical
section intermediate to the ends of the worm shaft 18 and having a surface
transverse, and preferably perpendicular, to the axis of the worm shaft 18
defines a worm shaft shoulder 40. When the worm shaft 18 is placed
through the aperture 20, the worm shaft shoulder 40 and the internal
shoulder 34 cooperate to prevent the outward axial motion of the worm 16.
Preferably, a bushing 42 is placed between the shaft shoulder
40 and the internal shoulder 34. The bushing 42 substantially prevents the
movement of air and water along the worm shaft 18 and through the
aperture 20 in the cover 12. The bushing 42 is preferably made of a
resilient material, such as plastic.
The arm 22 is rotatably mounted to the central post 28, with
the central post 28 extending through a circular aperture 44 in the arm 22.
Preferably, a tubular bearing 46 is disposed between the cover 12 and the
arm 22 along the central post 28. Most preferably, the bearing 46 is placed
in an interference fit with the cover 12, centering on a raised surface 47
protruding from the cover 12.
Preferably, the arm 22 has a first elongated end which is
attachable to the sash 26 and a partially circular second end 48 in which is
formed an integral worm gear 50. The worm gear 50~meshes with the worm
16, whereby rotation of the worm 16 causes the arm 22 to rotatably pivot
about the central post 28. Alternatively, a separate worm gear may be
disposed on the central post 28 and secured to the arm 22 such that
rotation of the worm 16, in mesh with the separate worm gear, causes the
arm 22 to pivot about the central post 28.
217 7 8 9 5 9 Case0186
-10-
The base 14, also preferably of die cast zinc manufacture, has
a central circular aperture 52 and four circular fastener post apertures 54
(see Figs. 3, 4, and 5). The central aperture 52 and the fastener post
apertures 54 correspond spatially with the central post 28 and the fastener
posts 30, respectively.
The base 14 has an angled tubular worm support surface 56
and a depressed trapezoidally-shaped stop support surface 58. The worm
support surface 56 mates with the tubular surface 32 and the stop surface
38 to define an enclosure 60 therebetween in which the worm 16 is
disposed. Together, the worm support surface 56, the internal shoulder 34,
the worm shoulder 40, the tubular support surface 32 and the stop surface
38 substantially prevent the axial and transverse motion of the worm 16.
The stop support surface 58 defines a depression in which the
stop 36 is seated. The stop support surface 58 substantially prevents the
movement of the stop 36 along the interior surface of the base 14 when the
base 14 is secured to the cover 12.
On the bottom side of the base 14 is formed a slot 62 of
rectangular cross-section which extends from one side of the base 14 to the
other. As shown in Fig. 7, a raised wall 64 of rectangular cross-section
extending along a sill 66 of a frame 68 fits substantially within the slot 62
when the operator 10 ins secured to the frame 68. The wall 64 prevents the
unobstructed flow of air and water along the bottom of the base 14 between
the base 14 and the sill 66. .
Additionally, a gasket 70 may be placed around an opening in
the sill 66 to ensure that a sealing surface is provided around the operator
10. When the operator 10 is secured to the sill 66, the gasket 70 fits
around a rearwardly facing edge 72 protruding from a rearwardly facing
surface of the cover 12 and the base 14. The gasket 70 ensures that a
920.00430
217 7 8 9 5 Case 186
-11-
water and airtight sealing condition is maintained between the operator 10
and the sill 66.
To ensure proper placement of the gasket 70, a special window
operator gasket fitting tool is used, shown generally as 74 in Figs. 8-11.
The tool 74 includes a support surface 76, a handle 78, and a raised central
portion 80. The support surface 76 has a raised outer edge 82, defining a
groove 84 between the outer edge 82 and the central portion 80.
During installation, the gasket 70, preferably made of
polyethylene foam with an adhesive backing, is placed on the fitting tool 74
so that the gasket 70 seats within the groove 84 (see Fig. 11 ). The fitting
tool 74 is then placed within the opening in the sill 66. In doing so, the
gasket 70 will be placed in the proper position for use with the operator 10
(see Fig. 12). Use of the tool 74 eliminates the need to apply the gasket 74
directly to the operator 10, which might cause some alignment difficulties.
Preferably, the operator is assembled as follows. The bushing
42 is placed on the worm shaft 18. The worm 16, thus assembled, is
disposed within the tubular surface 32 with the worm shaft 18 extending
through the aperture 20 and the first end of the worm 16 seated on the stop
surface 38. The bearing 46 is then placed on the central post 28, followed
by the arm 22. The arm 22 is positioned with the end 48 meshing with the
worm 16 so that the ar~rn 22 will lie parallel to the rear of the operator 10
in
a first position, and perpendicular to the rear of the operator 10 in a second
position when the worm 16 rotated: Finally, the base 14 is positioned with
the central post 28 and fastener posts 30 protruding through the central
aperture 52 and the fastener post apertures 54.
The posts 28, 30 are then formed and staked to fasten the
cover 12 to the base 14. To eliminate warpage of the parts in the operator
10, the central post 28 is secured first using a radial forming method. In
performing this radial forming method, a radial riveter is preferably used,
2177895 9Case0186
-12-
having a forming tool designed to create a flat surface on the center post
28. Through control of the time and force parameters, the axial play in the
assembled arm 22 can be greatly reduced, preferably to less than a 0.005
inch gap between components.
The specific settings for the time and force parameters will need
to be adjusted depending on the characteristics of the cover 12, the base
14, the center post 28, the arm 22 and the associated bearing 46. For
example, the parameters will necessarily vary with the arm thickness and the
amount of interference between the bearing 46 and the surface of the base
14 designed to receive the bearing 46. However, it has been found that
preferably the time required to perform the radial forming method varies
between 1 and 2.5 seconds, and that the force behind the forming tool
varies between 1200 and 2400 pounds.
After the central post 28 is formed, the fastener posts 30 are
preferably staked simultaneously, although alternatively the posts may be
staked in a number of different sequences, including individually, for
example. In particular, during the staking process, the operator 10 is held
stationary while four flat-faced punches are used to simultaneously impart
a significant force to the four fastener posts 30. The force imparted to the
fastener posts 30 causes the post material to extrude outwardly, thereby
securely fasting the cqrners of the cover 12 to the base 14.
This operator 10 has a number of advantages. The use of
mating surfaces on the cover 12 arid the base 14 to support the worm 16
and the arm 22 allows for the straight die cast manufacture of the cover 12
and the base 14 without use of paddles and cores. Additionally, by using
mating surfaces on the cover 12 and the base 14 to directly support the
worm 16, the number of pieces required for assembly of the operator 10 can
be reduced. Moreover, the use of mating surfaces on the cover 12 and the
21 l 7 8 9 5 920.00430
Case 786
-13
base 14 to secure the arm 22 allows for greater range of tolerances and
processes to be used to manufacture the arm 22 and associated gear.
Additionally, the elimination of the retainer bearing allows for
the placement of the bushing 42, substantially limiting the flow of air and
water through the enclosure 60, along the worm shaft 18 and out of the
operator 10. Moreover, the slot 62 and corresponding raised wall 64 on the
sill 66 cooperate to prevent air and water infiltration along the
operator/sill
interface in a highly effective fashion.
Furthermore, by spinning down the central post 28 first, and
then staking down the fastener posts 30, warpage of the parts and loss of
fit will be reduced or eliminated.
Still other aspects, objects and advantages of the present
invention can be obtained from a study of the specification, the drawings
and the appended claims.
